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SaferPak: Food Packaging Safety, Food Safety, Business Improvement and Quality Management
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Total Productive Maintenance (or Total Productive Manufacturing) is a continuous improvement strategy that embraces all aspects of an organisation. The father of TPM was Seiichi Nakajima, who pioneered the approach in Japan and exerted a major influence over the economic progress made by Japanese manufacturers from the late 1970's.

TPM is based on the experience that equipment and process problems are the root cause of many of the unplanned events that reinforce a reactive Management style. Delivering reliable equipment alone , however, is not enough to deliver world-class company performance. 'Maintenance' should encompass monitoring and improving the total integrity of the organisation through the people who add value - production and maintenance personnel alike.

Delivering Benchmark Levels of Business Excellence through TPM
The need to drive down costs and eliminate waste across the value / supply chain is well-accepted, as is the necessity to be open to all market and technology-driven opportunities. To meet these needs, 'excellent' companies require the right management environment and employee culture: and these can only be built up over time. What is the best way of building them? Quality management is a large part of the answer, and the European Foundation for Quality Management's Excellence Model™ (EFQM) provides a toolkit for carrying out a structured organisational health check. EFQM provides the essential checks and balances while Total Productive Manufacturing (TPM) is an 'enabling tool' to improve a company's score continuously on the model. Together, EFQM and TPM can give industry of all sizes and sectors a better means for gaining and then sustaining competitive advantage. This paper sets out the framework for using the tools together to release the productive potential of process equipment through the elimination of waste in all its forms.
Peter Willmott WCS International Ltd

TPM – I bet an operator can do this!
The industry is well aware of the impact of preventive maintenance. With downward cost and price pressure and aging equipment, many plants can barely keep fixing what breaks let alone perform simple equipment inspections with overtime-maxed maintenance people. The solution is clear. Break the vicious circle of reactive maintenance.
An obvious resource is to use early detection of problems by an operator. Who can better detect subtle equipment changes? Think about your automobile. Except scheduled maintenance, the automobile operator initiates 98% of shop visits. Most automobile operators also understand that finding problems early equals major savings.

TPM Implementation Experiences
This paper provides some information on the historical background of TPM introduction to Infineon Technologies followed by the chronicle events and experiences learnt in adopting and adapting TPM development activities to improve productivity in DS Business Unit. It also identifies some of the difficulties faced while implementing TPM and finally proposes some solutions for eliminating them.

Further reading

TPM for Every Operator (Shopfloor Series) - Japan Institute of Plant Maintenance

TPM for Every Operator (Shopfloor Series)
Japan Institute of Plant Maintenance

Total employee involvement is the foundation of a successful TPM program. To achieve the ultimate benefits of improving production quality, lowering costs, and improving commitment and morale, you need to educate all your employees - not just those in maintenance. This book focuses on explaining the TPM activities carried out by equipment operators themselves; autonomous maintenance, focused improvement, and safety initiatives. Anyone in your company who needs to understand TPM will benefit from reading this book.

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Autonomous Maintenance in Seven Steps: Implementing Tpm on the Shop Floor (TPM)
Masaji Tajiri, Fumio Gotoh

Autonomous Maintenance in Seven Steps: Implementing Tpm on the Shop Floor (TPM) - Masaji Tajiri, Fumio Gotoh

Written by two pioneers in autonomous maintenance development, this book gives more information on the concepts and implementation of the seven steps of autonomous maintenance than any other book available in English. Autonomous maintenance is an especially important pillar of Total Productive Maintenance (TPM) because it enlists the intelligence and skills of the people who are most familiar with factory machines: equipment operators. Operators learn the maintenance skills they need to know through a seven-step autonomous maintenance program. Most companies in the West stop after implementing the first few steps and never realise the full benefits of autonomous maintenance. This book contains comprehensive coverage of all seven steps, not just the first three or four.By treating machines as partners and taking responsibility for them, you get machines that you can rely on and help maintain an energized and responsive workplace. For companies that are serious about taking autonomous maintenance beyond mere cleaning programs, this is an essential sourcebook and Implementation support.This book: Includes an overview of autonomous maintenance features and checklists for step audits to certify team achievement at each AM step Covers TPM basics such as the six big losses, overall equipment effectiveness (OEE), causes of losses, and six major TPM activities Outlines an implementation plan for TPM and five countermeasures for achieving zero breakdowns Gives useful guidelines and case studies in applying AM to manual work such as assembly, inspection, and material handling Integrates examples from Toyota, Asai Glass, Bridgestone, Hitachi and other top companies. (Previously published as 'TPM Implementation')

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TPM in Process Industries (Step-By-Step Approach to TPM Implementation)
Tokutaro Suzuki

TPM in Process Industries (Step-By-Step Approach to TPM Implementation)  - Tokutaro Suzuki

Our most comprehensive book on TPM. What's the big deal? TPM - no three letters have ever had a more remarkable impact on profitability and equipment management. We're talking about a system so effective it can reduce equipment breakdowns to almost zero and increase worker productivity to 150 per cent. TPM is a plantwide, equipment-focused, team-based activity aimed at dramatically improving quality, manufacturing cost, and delivery time; involving everyone directly in equipment management issues. In this book, nine authors give you all the details you need to implement TPM, as well as specific applications and examples from chemical, food, textile and other process industries. This book takes you beyond the theory to actually help you plan and prepare the environment and select the right equipment. Any manager facing low operator/machine ratio, managing large equipment, or conducting extensive improvement activities will want to read this book. Selected Contents: Origin and Development of TPM. Overall Plant Effectiveness. What is Focused Improvement? Developing an Autonomous Maintenance Program. Equipment Management in Process Industries. Quality Maintenance. Education and Training in TPM. TPM in Administrative Support Departments. TPM and Safety and Environment Management. Zero accidents and Zero Pollution. TPM Small Group Activities. Measuring TPM Effectiveness. The PM Prize. (Also available in Spanish - call for details)

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Total Productive Maintenance (TPM) Articles
A link to dozens of excellent TPM articles from
The Plant Maintenance Resource Center...

Idcon TPM Library
The Idcon library provides Best Practice Articles in Maintenance Management, Reliability, Maintenance Technology, and Plant Engineering...







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